Fire-resistant shaft wall

ABSTRACT

A fire-resistant wall comprising studs and metal pans extending between the studs, disposed on one side of the wall, the studs and pans cooperating to form a temporary wall which may be finished by the inclusion of gypsum panels disposed between the pans and the studs, and other panels attached to the side of the studs opposite to the pan side of the wall.

United States Patent 1191 Crumbaugh et al.

[ Mar. 25, 1975 FIRE-RESISTANT SHAFT WALL [75] lnventors: John H.Crumbaugh, Des Plaines;

Maurice J. Marchello, Hickory Hills,

21 Appl.-No.: 411,935

[52] US. Cl. 52/495, 52/481 [51] Int. Cl E04b 2/78 [58] Field of Search52/495, 481, 281, 241,

11/1965 Downing 52/495 X 3,217,460 3,623,290 11/1971 D0wnlng.... 52/4813,707,818 1/1973 Nelsson 52/481 X Primar E.\'anzim'r-Price C. Faw, Jr.Attorney, Agent, or Firm-Samuel Kurlandsky; Stanton T. Hadley; KennethE. Roberts [5 7] ABSTRACT A fire-resistant wall comprising studs andmetal pans extending between the studs, disposed on one side of thewall, the studs and pans cooperating to form a temporary wall which maybe finished by the inclusion of gypsum panels disposed between the pansand the studs, and other panels attached to the side of the [56]References Cited studs opposite to the pan side of the wall.

UNITED STATES PATENTS 2,164,138 6/1939 London 52/481 X 6 Claims, 6Drawing Figures /0 30 3o 30' 52 1 1 i 48 l I J l v J -33 w ,flg r'tf'/flfifiXfi/ AP/QZW q 1 FIRE-RESISTANT SHAFT WALL BACKGROUND OF THEINVENTION 1. Field of the Invention Shaft walls are required for theenclosure of elevator shafts, smoke towers, air supply ducts andreturns, and the like, particularly in tall buildings. These may beconstructed either by a wet process, or a dry process using wallborad.The invention pretains to the latter, and specifically to a method forrendering the shaft side of the wall sufficiently fireresistant to givethe wall a -0 fire hazard classification that is, zero flame spread,zero fuel contributed, and zero smoke developed as determined by theMethod of Test of Surface Burning Characteristics of Building Materials,ASTM E 84.

2. Description of the Prior Art The oldest technique for building suchshaft walls was by the use of masonry. As disclosed in U.S. Pat. No.3,702,044, such techniques were time consuming, required the delivery ofheavy materials to high altitudes, and required dangerous scaffolding onthe shaft side of the wall. The other wet process, the use of plaster,generally suffered the same disadvantages. An early patent disclosingmetal pans in the construction of a plastered or concrete wall in U.S.Pat. No. 2,164,138. A recent development in plastering techniques did,however, eliminate the need for shaft-side processing. This was achievedby the use of metal pans on the shaft side of the wall, the other,accessivle side of the pans being attached to wire-web studs and metallath. Plaster was then sprayed into the space between the pan and thelath. However, as with masonry, the weight of the finished wall and thematerials therefor is excessive, and the plastering technique is a slowprocesss requiring highly paid labor.

In walls prepared from gypsum wallboard, conventional gypsum panelsalone have been faced with paper cover sheets which invariably smoke, ifnot form flames, in a fire. Such smoke generation may no longer beacceptable in municipalities having the strictest fire codes for shaftwalls.

Metal pans have been laminated to the outside of the 4 gypsum panels forwalls designed for general use. U.S. Pat-Nos. 3,548,557 and No.3,623,290 are representative ofsuch structures. The disadvantages ofthese constructions have been that they generally require a complicatedstud to cooperate with the metal pans. Furthermomre, the lamination ofthe pans to the gypsum panels is an additional processing step whichprevents the pans from being used along to create a temporary enclosureof the shaft.

A recently filed, copending U.S. application Ser. No. 298,3 14 filed onOct. 5, 1972, commonly owned with the instant application, discloses atype of metal pan that completely eliminates studs entirely, therebyeliminating one of the above-enumerated disadvantages. However, the panis still laminated to the panel.

SUMMARY OF THE INVENTION The invention pertains to a dry-assembledpaneled wall designed to be assembled from one side only, thereby makingit suitable for installation as a shaft wall. Further, it pertains to apan and a wall assembled therefrom with the metal pan disposed on theshaft side of the wall, thereby providing non fire-hazardous shaftlining. More specifically, there is provided a dryassembled wall oneside of which has the minimum fire hazard classification, comprising aplurality of spacedapart, elongate studs having longitudinal axes whichare substantially parallel, each stud comprising a web portion havingside margins, and a panel support member protruding from one face of theweb portion intermediate the side margins, the opposite face of the webportion being provided with a pocket, and plurality of metal pans, eachpan extending between two adjacent and spaced-apart studs, respectively,the pans being disposed on one exposed side of the wall, said pans eachcomprising a generally flat sheet and two opposing side margins, one ofsaid side margins being disposed adjacent to and in contact with one ofthe panel support members, the other of said side margins having aportion inserted within one of said pockets. A pan particularly suitedfor. this construction is provided, comprising a generally flat sheethaving a pair of opposed side margins disposed at an angle to saidsheet, one of said margins having a first portion thereof disposed so asto extend generally parallel to and away from said sheet and a secondportion thereof extending in a direction which is skewed to thedirection of extension of said first portion, said second portion beinghinged about a line which is spaced from said sheet a distancesufficient to accommodate a panel therebetween.

Accordingly, it is an object of the invention to provide afire-resistant wall and metal pans therefor which are suitable for useas shaft walls.

More specifically, it is an object of the invention to provide such awall and metal pan which can be assembled from one side only, whichpermit a temporary enclosure of the shaft, and which eliminate the smokegeneration that is otherwise characteristic of conventional gypsumpanels.

It is a related object of the invention to provide such a wall and metalpan therefor which require the use of only relatively simple studconstructions.

Other objects and advantages will become apparent upon reference to thefollowing description of the drawings and of the detailed embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a fragmentary horizontalsectional view through a wall constructed in accordance with theinvention;

FIG. 2 is an enlarged fragmentary sectional view illustrating thetemporary wall resulting from the first stage of the construction;

' FIG. 3 is a fragmentary elevational view of a metal pan used in theembodiment of FIGS. 1 and 2;

FIG. 4 is a fragmentary sectional view similar to FIG. 1, butillustrating an alternate embodiment of the invention;

FIG. 5 is a fragmentary sectional view taken generally along the line VVof FIG. 4, with the panel omitted; and

FIG. 6 is a fragmentary perspective view of the stud of FIG. 5.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Although the wall is describedhereinafter as particularly suited for a shaft wall enclosing elevatorshafts, stair wells, air return shafts, and the like, it can be used asany kind of wall, particularly where a 0-0-0 fire hazard classificationis required on the shaft side, or where the capability of a temporarilyfinished wall is required.

Referring now to FIG. 1, the wall comprises elongate, spaced-apart studs12, metal pans 30 having an exposed outer face 31 and an inner face 32,gypsum panels 42 releasibly and removably disposed adjacent to side 32of the pans, and wall panels 50 conventionally secured to the studs 12on the side of the wall opposite the pans. The gypsum panels 42 and 50are conventional, rehydrated gypsum cores with or without a paper coversheet or envelope. The longitudinal axes of the studs are preferablysubstantially parallel.

In accordance with the invention, the studs comprise a web portion 14having side margins 16 and 18, and exposed faces 20 and 22. A panelsupport member or rib 24 protrudes from face 20 intermediate the sidemargins. Two side flanges 26 and 28 may be formed so as to extend fromthe side margins, preferably from the face 20. The face 22 is providedwith a pocket 29. The overall configuration of stud 12 is thus one whichappears in cross section as an E.

As shown, stud 12 is formed by roll-forming, so that the pocket 29 is anatural result of the double fold of the web portion 14 which createsthe rib 24. Alterna tively, the stud may be extruded or otherwisemanufacturcd.

Metal pans 30 are positioned so as to extend between the studs 12, thusforming one side 33 of the wall. In the use of the wall as a shaft wall,side 33 is the shaft side. As best shown in FIGS. 2 and 3, the pans eachcomprise a flat sheet 34 having opposed side margins 36 and 38. Bothside margins are bent approximately perpendicularly to the sheet, andmargin 38 includes a portion 39 which is bent again so as to extendgenerally parallel to the sheet 34 and away therefrom. This portion 39is inserted into the pocket 29, while side margin 36 is disposed orpositioned adjacent to, and in contact with, the rib 24, within the sideflange 26.

The wall depicted by the solid lines in FIG. 2 thus represents atemporarily completed enclosure, particularly suited for closing offshafts. At a later date, the panels 42 may be removably inserted, in thedirection of arrow 44, with one edge 46 thereof being positioned betweenthe pans 30 and the rib 24 of the stud. The opposite edge 48 ispositioned adjacent to side margin 38 of the pan. To hold edge 48 inthis position, tab portions 49 may be provided, extending from theportions 39 of the pan 30. Prior to the insertion of the panels 42,these tabs are disposed so as to be approximately parallel to sidemargin 38, as shown in solid lines, FIG. 2. In this position, they donot interfere with the insertion of the panels. After the panels 42 areproperly positioned, tab portions 49 are bent about a line 51 to thephantom position shown in FIG. 2, thus extending in a direction oppositeto that of portion 39. In the phantom position, the tabs are spaced fromsheet 34 by the distance which accommodates the panel 42 between the taband the pan. As will be appreciated, the tabs may be readily formed by alancing operation.

At end 52 of the wall 10, the pans may be modified to take into accountthe termination of the wall at a conventional channel 54. Thus, sidemargin 38 may be eliminated altogether, creating a shortened pan 30'.

FIGS. 4-6 illustrate an alternate embodiment of the invention, whereinthe studs and the pans have been modified in shape, providing, however,the same resulting wall construction. Parts similar to those previouslydescribed bear the same reference numeral to which the distinguishingsuffix a has been added. Thus, wall 10a comprises studs 12a, metal pans30a defining side 33a of the wall, and gypsum panels 42a positionedadjacent to side 32a of the pans. The studs comprise, as before, a webportion 14a, a panel support member 24a, and side flanges 26a and 28a.Unlike the previous embodiment, the pocket 29a comprises the spacebetween an additional side flange 60 extending in the opposite directionfrom web portion 14a, and in the same plane, as extends flange 26a, andsupport members 62. Support members 62 preferably comprise tabs lancedout of the web (FIG. 5). As best shown in FIGS. 4 and 6, the tabs 62originally are disposed so as to project slightly out of the plane ofthe web. This disposition permits the ready insertion of panels 42a.Subsequently, the tabs 62 are bent from the phantom position, FIG. 4, tothe solid position, completing the pocket 290. I

I The complementarypans 30a of this embodiment omit the portions 39 ofthe side margin 38. Instead, side margins 36a and 38a comprise simplythe terminal edges of the sheet 34a which extend at an angle of about tothe sheet. Side margin 36a is disposed between side flange 26a and rib24a, while side margin 38a is inserted within the pocket 29a.

As with the previous embodiment, anchoring means are provided (FIG. 5)for securing the studs in proper horizontal position with respect to thehorizontal surfaces 68 at which the ends of the stud terminate. This maybe achieved by the conventional use of L-shaped floor and ceilingrunners 70, which may be conventionally secured to the surfaces 68.

It will also be appreciated that additional rows of gypsum panels may besecured to flanges 28a, as in the previous embodiment, to provide theopposite, room side of a completed wall.

The metal used to form the pans is not critical. The appropriate gaugedepends upon the size of the panel and conditions of use, and will bereadily apparent based on these design factors.

Although the invention has been described in connection with certainpreferred embodiments, it is not limited thereto. Rather, it is intendedthat it cover all equivalents, alternate arrangements, and embodimentsas may be included within the scope of the following claims.

What is claimed is:

1. A dry-assembled wall, one side of which has the minimum fire hazardclassification, comprising a plurality ofspaced-apart, elongate studshaving longitudinal axes which are substantially parallel, each studcomprising a web portion having side margins, and a panel support memberformed as a double fold protruding from one face of the web portionintermediate the side margins, the opposite face of the web portionbeing provided with a pocket defined by the inner surface of said doublefold, and a plurality of metal pans, each pan extending between twoadjacent and'spaced-apart studs, respectively, the pans being disposedon one exposed side of the wall,

said pans each comprising a generally flat sheet and two opposing sidemargins, one of said side margins being disposed adjacent to and incontact with one of the panel support members, the other of said sidemargins having a portion inserted within one of said pockets.

2. The wall as defined in claim 1, and further including gypsum panelsdisposed removably adjoining the pans, contained between the sheet andthe side margins of said pans,

said panels each having opposed edges, one of said edges beingpositioned between one of said pans and one of said studs,

and additional panels secured to said studs along one side marginthereof, defining the other exposed side of the wall.

3. The wall as defined in claim 2, wherein each of said studs furtherincludes a side flange projecting from one of said side margins and fromthe same web portion face as projects said member, said one pan sidemargin and said one gypsum panel edge being releasibly positionedbetween said member and said side flange.

4. The wall as defined in claim 1, wherein said side rnargin portionextends generally parallel to said sheet.

5. The wall as defined in claim 2, and further including a secondportion of said other pan side margin extending in a direction oppositeto the direction of the portion inserted within one of the pockets, theother of said vertical edges of each of said panels being disposed andretained between one of said pans and said second side margin portion.

6. The wall as defined in claim 2 and further including a second portionof said other pan side margin extending in a direction parallel to saidsheet and opposite to the direction of extension of said portioninserted within one of the pockets, whereby said other pan side marginsassist in retaining said pannels adjoining said pans.

1. A dry-assembled wall, one side of which has the minimum fire hazardclassification, comprising a plurality of spaced-apart, elongate studshaving longitudinal axes which are substantially parallel, each studcomprising a web portion having side margins, and a panel support memberformed as a double fold protruding from one face of the web portionintermediate the side margins, the opposite face of the web portionbeing provided with a pocket defined by the inner surface of said doublefold, and a plurality of metal pans, each pan extending between twoadjacent and spaced-apart studs, respectively, the pans being disposedon one exposed side of the wall, said pans each comprising a generallyflat sheet and two opposing side margins, one of said side margins beingdisposed adjacent to and in contact with one of the panel supportmembers, the other of said side margins having a portion inserted withinone of said pockets.
 2. The wall as defined in claim 1, and furtherincluding gypsum panels disposed removably adjoining the pans, containedbetween the sheet and the side margins of said pans, said panels eachhaving opposed edges, one of said edges being positioned between one ofsaid pans and one of said studs, and additional panels secured to saidstuds along one side margin thereof, defining the other exposed side ofthe wall.
 3. The wall as defined in claim 2, wherein each of said studsfurther includes a side flange projecting from one of said side marginsand from the same web portion face as projects said member, said one panside margin and said one gypsum panel edge being releasibly positionedbetween said member and said side flange.
 4. The wall as defined inclaim 1, wherein said side margin portion extends generally parallel tosaid sheet.
 5. The wall as defined in claim 2, and further including asecond portion of said other pan side margin extending in a directionopposite to the direction of the portion inserted within one of thepockets, the other of said vertical edges of each of said panels beingdisposed and retained between one of said pans and said second sidemargin portion.
 6. The wall as defined in claim 2 and further includinga second portion of said other pan side margin extending in a directionparallel to said sheet and opposite to the direction of extension ofsaid portion inserted within one of the pockets, whereby said other panside margins assist in retaining said pannels adjoining said pans.